Reassembly

2AR-FE CHARGING: GENERATOR: REASSEMBLY

1. INSTALL GENERATOR ROTOR ASSEMBLY

(a) Place the generator drive end frame on the generator pulley.





(b) Install the generator rotor to the generator drive end frame.

(c) Place the washer on the generator rotor.





2. INSTALL GENERATOR COIL ASSEMBLY

(a) Using a 21 mm socket wrench and press, slowly press in the generator coil.





(b) Install the 4 bolts.

Torque : 5.9 Nm (60 kgf-cm, 52 in-lbf)





3. INSTALL GENERATOR BRUSH HOLDER ASSEMBLY

(a) While pushing the 2 brushes into the generator brush holder, insert a 1.0 mm (0.039 in.) pin into the generator brush holder.





(b) Install the generator brush holder with the 2 screws.





Torque : 1.8 Nm (18 kgf-cm, 16 in-lbf)

(c) Pull the pin out of the generator brush holder.

4. INSTALL GENERATOR REAR END COVER

(a) Install the terminal insulator onto the generator coil assembly.





(b) Install the generator rear end cover with the 3 nuts.





Torque : 4.6 Nm (47 kgf-cm, 41 in-lbf)

5. INSTALL GENERATOR PULLEY WITH CLUTCH

(a) Temporarily install the generator pulley by hand.

(b) Mount the generator in a vise.

(c) Install SST (A) and (B) to the generator pulley as shown in the illustration.





SST : 09820-63021

(d) Using a wrench to hold SST (A), turn SST (B) clockwise to tighten the generator pulley.





without SST - Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)

with SST - Torque : 58 Nm (591 kgf-cm, 43 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 260 mm (10.24in.).
* This torque value is effective when SST is parallel to a torque wrench.

(e) Check that the generator pulley rotates smoothly.

6. INSTALL GENERATOR PULLEY CAP

(a) Install a new generator pulley cap to the pulley.